Plastic fastener, fastener clip, fastener dispensing tool and method of fastening objects

ABSTRACT

According to one embodiment, the plastic fastener comprises a flexible filament having a length of about 4.3 mm and a tensile strength of about 2 pounds, a first transverse bar located at one end of the flexible filament, and a second transverse bar located at the opposite end of the flexible filament. The fastener clip, which preferably does not contain a runner bar, comprises a plurality of identical fasteners of the aforementioned type, each of the fasteners being arranged in a parallel, side-by-side, spaced relationship. A connector post connects the first transverse bars of adjacent fasteners, and a connector post connects the second transverse bars of adjacent fasteners. An extra transverse bar is connected by a connector post to the first transverse bar of the last fastener, and another extra transverse bar is connected by a connector post to the second transverse bar of the last fastener, the extra transverse bars not being interconnected by a flexible filament.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 09/483,180, filed Jan. 13, 2000, now U.S. Pat. No.6,267,285, and a continuation-in-part of U.S. patent application Ser.No. 09/483,181, filed Jan. 13, 2000 now U.S. Pat. No. 6,418,597, andalso claims the benefit under 35 U.S.C. 119(e) of U.S. ProvisionalPatent Application Ser. No. 60/122,557, filed Mar. 2, 1999, thedisclosures of all the foregoing applications being incorporated hereinby reference.

BACKGROUND OF THE INVENTION

The present invention relates generally to the fastening of objectsusing plastic fasteners and relates more particularly to a novel plasticfastener, a novel fastener clip, a novel fastener dispensing tool and anovel method of fastening objects.

Certain articles of clothing, most notably men's dress shirts, are oftenpackaged and sold in a folded condition so as to minimize any wrinklingof the article and so as to present the article in an otherwiseflattering manner. Typically, the article is maintained in a foldedcondition by means of one or more straight metal pins, each of saidstraight metal pins typically comprising an elongated shaft terminatingat one end in a sharp tip designed to penetrate the article and at theother end in a rounded head designed not to penetrate the article.Typically in use, the article is folded, and a plurality of said pinsare used to maintain the article in its folded condition by securing thearticle to itself at a plurality of different locations. Often, in thecase of men's dress shirts, one or more of said pins are additionallyused to secure the shirt to a piece of cardboard or to a similar backingmaterial. The act of using straight metal pins to maintain an article ofclothing in a folded condition is typically referred to in the art as“shirt-pinning.”

Although straight metal pins have achieved widespread use in maintainingarticles of clothing in a folded condition, certain shortcomings areassociated therewith. One such shortcoming is that no suitable toolexists for dispensing such pins into an article of clothing;consequently, the pins must be inserted manually. As can readily beappreciated, the repeated insertion of such pins into articles ofclothing, over time, can become both physically and mentally taxing.Another shortcoming associated with the use of straight metal pins isthat the pins, as noted above, have sharp ends, which can cause injuryboth to the person who must insert the pin into the article and to theperson (i.e., consumer) who must remove the pin from the article.Moreover, once the pins are removed from the article, they must bedisposed of properly to avoid injury to others. Still anothershortcoming associated with the use of straight metal pins is that suchpins, when inserted, may cause damage to the article, either by snaggingand tearing the article or by creating a conspicuous insertion hole inthe article. Still yet another shortcoming associated with the use ofstraight metal pins is that such pins, once inserted into an article ofclothing, can be difficult to access and manipulate in such a way as toenable their removal.

Plastic fasteners of the type comprising an elongated flexible filamenthaving a first enlargement at one end thereof and a second enlargementat the opposite end thereof are well-known and have been widely used inthe attachment of merchandise tags to articles of commerce, in thecoupling or re-coupling of buttons to garments, in the binding of a shoeupper during the process of shoe-lasting, and in various packagingapplications. In one common type of plastic fastener (see, for example,FIG. 1 of U.S. Pat. No. 5,321,872, which patent is incorporated hereinby reference), the first enlargement has the shape of a first transversebar and the second enlargement has the shape of a paddle or the shape ofa second transverse bar, the first transverse bar and the paddle (orsecond transverse bar) extending in planes parallel to one another. Inanother common type of plastic fastener (see, for example, U.S. Pat. No.3,494,004, which patent is incorporated by reference), the firstenlargement has the shape of a transverse bar and the second enlargementhas the shape of a knob or pin head. In still another common type ofplastic fastener (see, for example, U.S. Pat. No. 4,240,183, whichpatent is incorporated herein by reference), the first enlargement hasthe shape of a transverse bar or the shape of a plug and the secondenlargement has the shape of a socket, said socket being adapted toreceive said transverse bar or said plug.

Plastic fasteners of the various types described above are typicallymolded as parts of a unitary fastener clip. An example of such afastener clip is disclosed in U.S. Pat. No. 3,733,657, which patent isincorporated herein by reference. The clip of the aforementioned '657patent includes a plurality of fasteners, each of said fastenerscomprising a flexible filament having a first transverse bar (or“cross-bar”) at one end thereof and a paddle or a second transverse bar(or “cross-bar”) at the opposite end thereof, the transverse bar and thepaddle (or second transverse bar) of each fastener extending in planesparallel to one another. The fasteners are arranged relative to oneanother so that the respective transverse bars are spaced apart andoriented side-by-side and parallel to one another and so that therespective paddles (or second transverse bars) are spaced apart andoriented side-by-side and parallel to one another. The clip of theforegoing '657 patent also includes a runner bar, said runner barextending perpendicularly relative to the respective transverse bars andbeing connected to each of the transverse bars by a severable connector.The clip of said '657 patent further includes a severable memberinterconnecting each pair of adjacent paddles (or second transversebars).

Several commercial embodiments of the aforementioned fastener clip havebeen sold by the present assignee, Avery Dennison Corporation, asDENNISON® SWIFTACH® fastener clips. DENNISON® SWIFTACH® fastener clipscomprising fasteners of the type having a cross-bar at one end of aflexible filament and a paddle at the opposite end of the flexiblefilament are generally made of polypropylene or nylon and are typicallyused to attach merchandise tags and the like to articles of clothing.The filaments of such fasteners are typically at least about 12.5 mm inlength. DENNISON® SWIFTACH® fastener clips comprising fasteners of thetype having a first cross-bar at one end of a flexible filament and asecond cross-bar at the opposite end of the flexible filament are madeof nylon and are used to attach merchandise tags and the like to a widevariety of articles of commerce. In addition, such fasteners are used inshoe-lasting applications and in packaging applications, where the hightensile strength afforded by the use of nylon in the fastener isdesirable. The filaments of such fasteners are typically at least about6.35 mm in length.

As far as the present inventors are aware, the above-described fastenerclip, exemplified by the family of DENNISON® SWIFTACH® fastener clips,has not been used to maintain an article of clothing, such as a dressshirt, in a folded condition.

A second type of fastener clip (or “fastener stock”) is disclosed inU.S. Pat. No. 4,039,078, inventor Bone, issued Aug. 2, 1977, whichpatent is incorporated herein by reference. In said patent, the fastenerstock comprises two undivided elongated and continuous plastic sidemembers having a plurality of plastic cross links coupled to and betweeneach of said side members, each of the links being preferably spacedequidistantly apart from each other The fastener stock is designed to beseparated or divided, e.g., by cutting, severing, rupturing or shearingthe side members, to provide a plurality of fasteners, each of saidfasteners preferably having a substantially H shape.

A commercial embodiment of the aforementioned fastener stock has beensold by the present assignee, Avery Dennison Corporation, as DENNISON®PLASTIC STAPLE™ fasteners. PLASTIC STAPLE™ fasteners are typically madeof polyurethane and are often used to attach tags, at two distinctpoints, to pants and similar clothing articles. It is the understandingof the present inventors that, for a limited time in the past, a thirdparty used PLASTIC STAPLE™ fasteners to “pin” shirts, albeit not dressshirts or other shirts of a fine material, so as to maintain the shirtsin a folded condition. It is the understanding of the present inventorsthat the aforementioned securing was achieved using a dual needlefastener dispensing tool of the type disclosed in U.S. Pat. No.4,533,076 and was performed by folding the shirt, inserting both needlesof the tool entirely through the folded-over article and then dispensingboth cross-bars through the needles and the folded article so that bothcross-bars were positioned on one side of the article, with the filamentconnecting the two cross-bars extending over to the opposite side of thearticle. It is further believed by the present inventors that theaforementioned use of such fasteners to “pin” shirts was discontinuedbecause PLASTIC STAPLE™ fasteners did not have sufficient tensilestrength to maintain the shirt in its folded condition (PLASTIC STAPLE™fasteners typically having a tensile strength of about 1.2-1.4 pounds).

Tools (often referred to as “tagging guns”) for dispensing individualfasteners from multi-fastener clips of the two different types describedabove are known, examples of such tools including the Dennison® Mark II™SWIFTACH® tool, as well as those tools disclosed in U.S. Pat. Nos.5,772,073, 5,683,025, 5,024,365, 4,533,076, 4,456,161, 4,121,487, and4,456,123, all of which are incorporated herein by reference.

Other patents that may be of interest include U.S. Patent No. 3,103,666,inventor Bone, issued Sep. 17, 1963; U.S. Pat. No. 5,593,033, inventorKunreuther, issued Jan. 14, 1995; U.S. Pat. No. 5,463,799, inventorGraham, issued Nov. 7, 1995; U.S. Pat. No. 5,321,872, inventor Merser,issued Jun. 21, 1994; U.S. Pat. No. 3,733,657, inventor Lankton, issuedMay 22, 1973, U.S. Pat. No. 4,660,718, inventor Kato et al., issued Apr.28, 1987; and U.S. Reissue Patent No. 32,332, inventor Kato, re-issuedJan. 20, 1987, all of which are incorporated herein by reference.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a novel plasticfastener.

Therefore, according to one aspect of the invention, a plastic fasteneris provided, said plastic fastener comprising (a) a flexible filament,said flexible filament having a first end and a second end, saidflexible filament having a tensile strength of about 2-4 lbs; (b) aninserting element disposed at said first end, said inserting elementbeing dimensioned to permit its insertion through a garment and, onceinserted therethrough, to be retained by said garment; and (c) aretaining element disposed at said second end, said retaining elementbeing dimensioned to prevent said flexible filament from being pulledcompletely through said garment.

According to another aspect of the invention, a plastic fastener isprovided, said plastic fastener comprising (a) a flexible filament, saidflexible filament having a first end and a second end, said flexiblefilament having a tensile strength of about 2 lbs., a length ofapproximately 4.3 mm, and a diameter of approximately 0.2 mm; (b) afirst transverse bar disposed at said first end; and (c) a secondtransverse bar disposed at said second end; (d) wherein each of saidfirst and second transverse bars has a length of approximately 1.8 mm, awidth of approximately 0.5 mm and a height of approximately 0.5 mm.

According to still another aspect of the invention, a plastic fasteneris provided, said plastic fastener comprising (a) a flexible filament,said flexible filament having a first end and a second end, saidflexible filament having a length of approximately 3-5 mm; (b) aninserting element disposed at said first end, said inserting elementbeing dimensioned to permit its insertion through a garment and, onceinserted therethrough, to be retained by said garment; and (c) aretaining element disposed at said second end, said retaining elementbeing dimensioned to prevent said flexible filament from being pulledcompletely through said garment.

It is another object of the present invention to provide a novelfastener clip.

Therefore, according to one aspect of the invention, a fastener clip isprovided, said fastener clip comprising (a) a first fastener, said firstfastener comprising a flexible filament having a first enlarged end anda second enlarged end, said flexible filament having a length ofapproximately 3-5 mm; (b) a second fastener, said second fastenercomprising a flexible filament having a first enlarged end and a secondenlarged end, (c) said first fastener and said second fastener beingarranged in a parallel, side-by-side, spaced relationship; (d) a firstconnector post connecting said first enlarged end of said first fastenerto said first enlarged end of said second fastener, and (e) a secondconnector post connecting said second enlarged end of said secondfastener to said second enlarged end of said second fastener.

According to another aspect of the invention, a fastener clip isprovided, said fastener clip comprising (a) a first fastener, said firstfastener comprising a flexible filament having a first enlarged end anda second enlarged end, said flexible filament having a tensile strengthof approximately 2-4 lbs.; (b) a second fastener, said second fastenercomprising a flexible filament having a first enlarged end and a secondenlarged end; (c) said first fastener and said second fastener beingarranged in a parallel, side-by-side, spaced relationship; (d) a firstconnector post connecting said first enlarged end of said first fastenerto said first enlarged end of said second fastener; and (e) a secondconnector post connecting said second enlarged end of said secondfastener to said second enlarged end of said second fastener.

According to still another aspect of the invention, a fastener clip isprovided, said fastener clip comprising (a) a first fastener, said firstfastener comprising a flexible filament having a first enlarged end anda second enlarged end, said flexible filament having a tensile strengthof approximately 2 lbs. and a length of approximately 4.3 mm; (b) asecond fastener, said second fastener comprising a flexible filamenthaving a first enlarged end and a second enlarged end; (c) said firstfastener and said second fastener being identical to one another andbeing arranged in a parallel, side-by-side, spaced relationship; (d) afirst connector post connecting said first enlarged end of said firstfastener to said first enlarged end of said second fastener; and (e) asecond connector post connecting said second enlarged end of said secondfastener to said second enlarged end of said second fastener.

According to still yet another aspect of the invention, a fastener clipis provided, said fastener clip comprising (a) a first fastener, saidfirst fastener comprising (i) a flexible filament having a first end anda second end, (ii) a first enlargement disposed at said first end, and(iii) a second enlargement disposed at said second end; (b) a thirdenlargement: said third enlargement being severably connected to saidfirst enlargement; (c) a fourth enlargement, said fourth enlargement notbeing directly interconnected to said third enlargement, said fourthenlargement being severably connected to said second enlargement.

It is still yet another object of the present invention to provide anovel method of fastening objects.

Therefore, according to one aspect of the invention, there is provided amethod of fixing an article of clothing to itself, said methodcomprising the steps of (a) providing a plastic fastener, said plasticfastener comprising (i) a flexible filament, said flexible filamenthaving a first end, a second end, and a length, said length beingsuitable to fixedly retain the article of clothing against itself, (ii)an inserting element disposed at said first end, said inserting elementbeing dimensioned to enable its insertion through the article ofclothing and, once inserted therethrough, to be retained by the articleof clothing, and (iii) a retaining element disposed at said second end,said retaining element being dimensioned to prevent said flexiblefilament from being pulled completely through the article of clothing,and (b) inserting said inserting element of said plastic fastener intoand completely through the article of clothing at at least a pair oflocations therein, with said retaining element not being inserted intothe article of clothing.

According to another aspect of the invention, a method of fixing anarticle of commerce to a support is provided, said method comprising thesteps of (a) providing a plastic fastener, said plastic fastenercomprising (i) a flexible filament, said flexible filament having afirst end, a second end and a length, said length being suitable tofixedly retain the article against the support, (ii) an insertingelement disposed at said first end, said inserting element beingdimensioned to enable its insertion through the article of commerce andthe support and, once inserted therethrough, to be retained thereby, and(iii) a retaining element disposed at said second end, said retainingelement being dimensioned to prevent said flexible filament from beingpulled completely through the article of commerce and the support, and(b) inserting said inserting element of said plastic fastener into andcompletely through the article of commerce and the support, with saidretaining element not being inserted into either the article or thesupport, in such a way as to fix the article of commerce to the support.

According to still another aspect of the invention, a method of couplingan article of commerce to a support is provided, said method comprisingthe steps of (a) providing a plastic fastener, said plastic fastenercomprising (i) a flexible filament, said flexible filament having afirst end, a second end, a tensile strength of approximately 2-4 lbs.and a length of approximately 3-5 mm; (ii) an inserting element disposedat said first end, said inserting element being dimensioned to enableits insertion through the article of commerce and the support and, onceinserted therethrough, to be retained thereby, and (iii) a retainingelement disposed at said second end, said retaining element beingdimensioned to prevent said flexible filament from being pulledcompletely through the article of commerce and the support in thedirection of said inserting element; and (b) inserting said insertingelement of said plastic fastener into and completely through the articleof commerce and the support.

According to still yet another aspect of the invention, a method offixing together two elements is provided, said method comprising thesteps of (a) providing a plastic fastener, said plastic fastenercomprising (i) a flexible filament, said flexible filament having afirst end, a second end, a length and a tensile strength, said lengthbeing suitable to fix the two elements together, said tensile strengthbeing sufficiently strong to keep the two elements fixed together duringnormal handling and yet sufficiently weak to enable the two elements tobe separated from one another without being damaged by said plasticfastener merely by having the two elements pulled away from each otheruntil said flexible filament breaks, (ii) an inserting element disposedat said first end, said inserting element being dimensioned to enableits insertion through the two elements and, once inserted therethrough,to be retained by the two elements, and (iii) a retaining elementdisposed at said second end, said retaining element being dimensioned toprevent said flexible filament from being pulled completely through thetwo elements, and (b) inserting said inserting element of said plasticfastener into and completely through the two elements, with saidretaining element not being inserted into the two elements.

According to a further aspect of the invention, a method of couplingtogether two or more sheets of paper is provided, said method comprisingthe steps of (a) providing a plastic fastener, said plastic fastenercomprising (i) a flexible filament, said flexible filament having afirst end, a second end, a length and a tensile strength, said tensilestrength being sufficiently strong to keep the sheets of paper coupledtogether during normal handling and yet sufficiently weak to enable thesheets of paper to be separated from one another without being damagedby said plastic fastener merely by pulling the sheets of paper away fromeach other until said flexible filament breaks, (ii) an insertingelement disposed at said first end, said inserting element beingdimensioned to enable its insertion through the sheets of paper and,once inserted therethrough, to be retained by the sheets of paper, and(iii) a retaining element disposed at said second end, said retainingelement being dimensioned to prevent said flexible filament from beingpulled completely through the sheets of paper; and (b) inserting saidinserting element of said plastic fastener into and completely throughthe sheets of paper, with said retaining element not being inserted intothe sheets of paper.

It is still yet another object of the present invention to provide anovel fastener dispensing tool.

Therefore, according to one aspect of the invention, there is provided ahandheld fastener dispensing tool for dispensing a fastener of the typecomprising a flexible filament having an enlargement at one end thereof,said fastener dispensing tool comprising (a) a casing, said casing beingprovided with a needle opening; (b) a hollow, slotted needle, saidhollow, slotted needle being slidably movable back and forth between aretracted position disposed entirely within said casing and an extendedposition extending through said needle opening, said hollow, slottedneedle being adapted to receive the enlargement of said fastener; (c) anejector rod, said ejector rod being slidably movable back and forththrough said hollow, slotted needle to eject the enlargement disposedtherein; and (d) an anvil coupled to said casing and extending in frontof said needle opening, said anvil being positioned so that said hollow,slotted needle, when in said extended position, does not extendtherebeyond.

According to another aspect of the invention, there is provided afastener dispensing tool, said fastener dispensing tool comprising (a) agun-shaped casing, said gun-shaped casing comprising a handle portionand a barrel portion, said barrel portion being provided with anopening; (b) a needle carrier, said needle carrier being slidablymounted in said barrel portion; (c) a hollow, slotted needle, saidhollow, slotted needle being coupled to said needle carrier and beinginsertable back and forth through said opening in said casing; (d) anejector rod carrier, said ejector rod carrier being slidably mounted insaid barrel portion; (e) an ejector rod, said ejector rod being coupledto said ejector rod carrier and being insertable back and forth throughsaid hollow, slotted needle; (f) a linking member coupled to said needlecarrier and selectively engageable with said ejector rod carrier forcoupling and decoupling said needle carrier to and from said ejector rodcarrier so that said needle carrier is caused to slide back and forth insaid barrel portion only during a portion of the movement of saidejector rod carrier; and (g) a triggering mechanism, said triggeringmechanism comprising a trigger, said trigger being pivotally mounted insaid casing and extending partially through said handle portion thereoffor manual actuation, said triggering mechanism further comprising alever disposed within said casing, said lever being pivotally mounted ata first end on a first pin, said first pin being fixed to said trigger,said lever being pivotally mounted at a second end on a second pin, saidsecond pin being fixed to said ejector rod carrier.

According to yet another aspect of the invention, there is provided afastener dispensing tool for dispensing individual fasteners from afastener clip, said fastener dispensing tool comprising (a) a casing,said casing being provided with an opening: (b) a hollow, slottedneedle, said hollow, slotted needle being slidably movable back andforth through said opening in said casing; (c) an ejector rod, saidejector rod being slidably movable back and forth through said hollow,slotted needle; and (d) a feed guide, said feed guide being stationarilymounted in said casing behind said hollow, slotted needle, said feedguide defining a front portion of a feed track and comprising a stage atthe end of said feed track off of which an individual fastener from afastener clip is loaded into said hollow, slotted needle by said ejectorrod.

According to still yet another aspect of the invention, there isprovided a fastener dispensing tool for dispensing individual fastenersfrom a fastener clip, said fastener dispensing tool comprising (a) acasing, said casing being provided with an opening; (b) a hollow,slotted needle, said hollow, slotted needle being slidably movable backand forth between a retracted position and an extended positionextending through said opening in said casing; (c) an ejector rod, saidejector rod being slidably movable back and forth between a withdrawnposition disposed behind said hollow, slotted needle and an advancedposition extending through said hollow, slotted needle; (d) a triggermechanically coupled to said casing; (e) first coupling means, couplingsaid trigger to said hollow, slotted needle, for moving said hollow,slotted needle from said retracted position to said extended positionand then back to said retracted position during a trigger stoke; and (f)second coupling means, coupling said trigger to said ejector rod, formoving said ejector rod from said withdrawn position to said advancedposition and then back to said withdrawn position during a triggerstoke; (g) wherein said first coupling means and said second couplingmeans are designed so that said ejector rod withdraws from said advancedposition together with said hollow, slotted needle as said hollow,slotted needle moves from said extended position to said retractedposition.

According to a further aspect of the invention, there is provided afastener dispensing tool, said fastener dispensing tool comprising (a) acasing, said casing being shaped to receive, entirely within saidcasing, a clip of fasteners, each of said fasteners in said clipcomprising a flexible filament having a first enlarged portion at afirst end thereof and a second enlarged portion at a second end thereof;(b) exactly one hollow, slotted needle coupled to said casing, saidhollow, slotted needle being adapted to receive the first enlargedportion of a fastener: and (c) an ejector rod disposed within saidcasing and insertable into said hollow, slotted needle for ejecting fromsaid hollow, slotted needle an enlarged portion of a fastener disposedtherein.

According to still a further aspect of the invention, there is provideda fastener dispensing tool, said fastener dispensing tool comprising (a)a casing, said casing being shaped to receive, entirely within saidcasing, a clip of fasteners, each of said fasteners in said clipcomprising a flexible filament having a first enlarged portion at afirst end thereof and a second enlarged portion at a second end thereof;(b) a hollow, slotted needle coupled to said casing, said hollow,slotted needle being adapted to receive the first enlarged portion of afastener; (c) wherein said feed track terminates behind said hollow,slotted needle in a direction substantially perpendicular to thelongitudinal axis of said hollow, slotted needle; and (d) an ejector roddisposed within said casing and insertable into said hollow, slottedneedle for ejecting from said hollow, slotted needle an enlarged portionof a fastener disposed therein.

Additional objects, features, aspects and advantages of the presentinvention will be set forth, in part, in the description which followsand, in part, will be obvious from the description or may be learned bypractice of the invention. In the description, reference is made to theaccompanying drawings which form a part thereof and in which is shown byway of illustration specific embodiments for practicing the invention.These embodiments will be described in sufficient detail to enable thoseskilled in the art to practice the invention, and it is to be understoodthat other embodiments may be utilized and that structural changes maybe made without departing from the scope of the invention. The followingdetailed description is, therefore, not to be taken in a limiting sense,and the scope of the present invention is best defined by the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are hereby incorporated into andconstitute a part of this specification, illustrate preferredembodiments of the invention and, together with the description, serveto explain the principles of the invention. In the drawings wherein likereference numerals represent like parts:

FIGS. 1(a) through 1(c) are side, top and front views, respectively, ofone embodiment of a plastic fastener well-suited for maintaining a dressshirt in a folded condition in accordance with the teachings of thepresent invention;

FIGS. 2(a) and 2(b) are partially-exploded perspective andpartially-exploded side views, respectively, of one embodiment of afastener clip constructed in accordance with the teachings of thepresent invention, the fastener clip including a plurality of theplastic fasteners shown in FIGS. 1(a) through 1(c);

FIGS. 3(a) through 3(c) are side, top and front views, respectively, ofan individual fastener of the clip of FIG. 2, together with itsassociated connectors;

FIGS. 4(a) through 4(c) are left side, front right top perspective andfront views, respectively, of one embodiment of a fastener dispensingtool constructed according to the teachings of the present invention,the fastener dispensing tool being well-suited for use in dispensingindividual fasteners from the clip of FIG. 2;

FIG. 5 is a rear, left, top, perspective view of the fastener dispensingtool of FIGS. 4(a) through 4(c), with the left half of the casing notbeing shown;

FIGS. 6(a) through 6(d) are front right bottom perspective, front lefttop perspective, enlarged left side and enlarged front views,respectively, of the right half of the casing of the tool shown in FIGS.4(a) through 4(c);

FIGS. 7(a) through 7(d) are front left bottom perspective, front righttop perspective, enlarged right side and enlarged front views,respectively, of the left half of the casing of the tool shown in FIGS.4(a) through 4(c);

FIGS. 8(a) through 8(d) are front right top perspective, bottom, sectionand right views, respectively, of the cover of the tool shown in FIGS.4(a) through 4(c);

FIGS. 9(a) through 9(d) are rear right top perspective, right side, rearand top perspective views, respectively, of the anvil of the tool shownin FIGS. 4(a) through 4(c);

FIGS. 10(a) through 10(c) are rear left top perspective, front right topperspective and right side views, respectively, of the needle shown inFIG. 5,

FIGS. 11(a) through 11(f) are front left top perspective, front righttop perspective, rear right bottom perspective, top, front and sectionviews, respectively, of the needle carrier shown in FIG. 5,

FIG. 12 is an enlarged perspective view of the locking pin shown in FIG.5;

FIG. 13 is a left rear bottom perspective view of the tool shown in FIG.5, with the left half of the casing, the needle carrier, the trigger andcertain additional components not being shown for clarity;

FIGS. 14(a) and 14(b) are front bottom left perspective and right sideviews, respectively, of the ejector rod carrier shown in FIG. 5;

FIG. 15 is a rear top right perspective view of the ejector clip shownin FIG. 5;

FIG. 16 is a rear top right perspective view of the linking member shownin FIG. 5;

FIGS. 17(a) through 17(c) are front bottom right perspective, rear topleft perspective and right side views, respectively, of the feed guideshown in FIG. 5;

FIGS. 18(a) and 18(b) are front bottom right perspective and frontviews, respectively, of the feed clip shown in FIG. 13;

FIG. 19 is a front top right perspective view of the pawl shown in FIG.13; and

FIG. 20 is a front bottom left perspective view of the feed slidingmember shown in FIG. 13.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring now to FIGS. 1(a) through 1 (c), there are shown side, top andfront views, respectively, of one embodiment of a plastic fastenerwell-suited for maintaining a dress shirt in a folded condition, saidplastic fastener being constructed according to the teachings of thepresent invention and being represented generally by reference numeral11 (It is to be understood that, although fastener 11 is particularlywell-suited for maintaining a dress shirt or the like in a foldedcondition, it is not limited in its utility thereto and may be used in avariety of different applications including, but not limited to, fixingtogether pairs of socks, coupling together sheets of paper, fixing dressshirts to cardboard supports, fixing doll clothing to cardboardsupports, etc.)

Fastener 11, which is a unitary structure preferably made by molding,comprises a flexible filament 13. When molded, filament 13 has a lengthl_(t) of about 1.65 mm and a diameter d₁ of about 0.4 mm; filament 13 isthereafter stretched in the conventional manner to a length ofapproximately 4.3 mm and a diameter of approximately 0.2 mm. It shouldbe noted that, even though, in the present embodiment, filament 13 has agenerally cylindrical shape, filament 13 need not be cylindricallyshaped and may take a variety of shapes, including those specified incommonly-assigned co-pending U.S. patent application Ser. No.09/416,784.

Fastener 11 also comprises a first cross-bar 15 and a second cross-bar17, cross-bar 15 being disposed at a first end of filament 13, cross-bar17 being disposed at a second end of filament 13, cross-bars 15 and 17being parallel to one another. Each of cross-bars 15 and 17 has a lengthl₂ of approximately 1.78 mm, a width w₁ of approximately 0.55 mm and aheight h₁ of approximately 0.55 mm. It should be noted that, eventhough, in the present embodiment, cross-bars 15 and 17 are shaped so asto have flat inner surfaces 15-1 and 17-1, respectively, proximate tofilament 13 and convex outer surfaces 15-2 and 17-2, respectively,distal to filament 13, cross-bars 15 and 17 need not be so shaped. Infact, cross-bars 15 and 17 may take a variety of forms, including thoseof the enlarged ends described in U.S. patent application Ser. No.09/416,784.

Fastener 11 is preferably made of a polyurethane that gives filament 13a tensile strength of about 2 pounds. However, it is to be noted thatsaid polyurethane is not the only type of material of which fastener 11may be made and that other plastic materials (or combinations ofmaterials) capable of providing filament 13 with a tensile strength inthe range of about 2-4 pounds (or whatever tensile strength is desirablebased upon the particular use to which fastener 11 is put) are alsosuitable for purposes of the present invention. It is to be noted that,because filament 13 is made of a polyurethane, it has a certain degreeof elasticity—a property which may be desirable in certain applications.

Referring now to FIGS. 2(a) and 2(b), there are shown partially-explodedperspective and partially-exploded side views, respectively, of oneembodiment of a fastener clip constructed according to the teachings ofthe present invention, the fastener clip being represented generally byreference numeral 31.

Clip 31, which is a unitary structure preferably made by molding,comprises a plurality of fasteners 11-1 through 11-3, fasteners 11 beingarranged in a parallel, side-by-side, spaced orientation. Although onlythree fasteners 11 are shown in clip 31, it is to be understood that thenumber of fasteners 11 in clip 31 is illustrative only and could beincreased or decreased without departing from the spirit or scope of thepresent invention. (In fact, in a preferred embodiment, clip 31comprises one hundred twenty-five fasteners 11.)

Clip 31 also includes a first plurality of severable connector posts33-1 and 332 and a second plurality of severable connector posts 35-1and 35-2, connector posts 33 connecting the mutually-opposing sides ofadjacent cross-bars 15 at their approximate midpoints and extending in asubstantially perpendicular direction relative to the longitudinal axesof cross-bars 15, connector posts 35 connecting the mutually-opposingsides of adjacent cross-bars 17 at their approximate midpoints andextending in a substantially perpendicular direction relative to thelongitudinal axes of cross-bars 17. (Side, top and front views of anindividual fastener 11, together with its associated connector posts 33and 35, are shown in FIGS. 3(a) through 3(c), respectively.) In thepresent embodiment, connector posts 33 and 35 have a length ofapproximately 0.25 mm.

Connector posts 33 and 35 are strong enough to maintain the connectionbetween adjacent fasteners 11 in clip 31 prior to the dispensing ofindividual fasteners 11 from clip 31 and, yet, are weak enough to besevered by the conventional severing action of a fastener dispensingtool. At the same time, connector posts 33 and 35 have a certain degreeof flexibility; consequently, because of the arrangement of posts 33 and35 relative to cross-bars 15 and 17, respectively, adjacent fasteners 11in clip 31 are permitted to pivot relative to one another, therebyenabling clip 31 to be bent into an arcuate shape.

As seen best in FIG. 2(b), posts 33 and 35 preferably have a conical ortapered transverse cross-section that decreases in diameter from thefastener about to be dispensed (e.g., fastener 11-1) to the nextfastener in the clip 31 (e.g., fastener 11-2) so that very little ornothing of the severed posts 33 and 35 that once connected the fastenerabout to be dispensed to the fastener previously attached to it remainon the about-to-be-dispensed fastener. In this manner, as will be seenbelow, the fastener about to be dispensed by the tool (e.g., fastener11-1) is able to sit substantially flush within a tool used to dispensethe fastener. It should be understood, however, that the aboveembodiment is merely a preferred embodiment and that posts 33 and 35need not be conical or tapered and, instead, may take a variety ofshapes.

Clip 31 further includes an extra pair of cross-bars 37 and 39,cross-bars 37 and 39 being identical to cross-bars 15 and 17,respectively, except for the fact that cross-bars 37 and 39 are notdisposed at the ends of a flexible filament. Cross-bars 37 and 39 arearranged in a parallel, side-by-side, spaced orientation from cross-barsand 17, respectively, of the last fastener 11 of clip 31 (in the presentembodiment, fastener 11-3) and are severably connected thereto byconnector posts 33-3 and 353, respectively. Connector post 33-3 isidentical to connector posts 33-1 and 33-2, and connector post 35-3 isidentical to connector posts 35-1 and 35-2. Cross-bars 37 and 39 serveto keep the last fastener of clip 31 properly oriented while it is beingdispensed using the fastener dispensing tool described below.

As can be seen in FIGS. 2(a) and 2(b), clip 31 does not include a runnerbar. This may be advantageous since the runner bar of a fastener cliptypically has no use once the fasteners originally attached thereto havebeen dispensed therefrom. As a result, the detached runner bar typicallyrepresents economically and environmentally undesirable waste material.In addition, severed connectors previously used to connect fasteners toa runner bar and still remaining on the runner bar after the fastenershave been detached therefrom often have an acute end which mayundesirably snag on and damage merchandise when fasteners from thefastener clip are dispensed into such merchandise with a conventionalfastener dispensing tool.

Clip 31 may be made by injection molding, preferably using polyurethaneor a similar material. According to a preferred embodiment, clip 31 ismade by forming a fastener clip analogous to clip 31 but furthercomprising a runner bar severably connected to each of cross-bars 15(see, for example, fastener clip 11 of U.S. Ser. No. 09/464,022) andthen by severing said runner bar from each of cross-bars 15 and removingthe remnants of any connectors connecting said runner bar to cross-bars15.

It should be noted that, notwithstanding the above-noted generalizedshortcomings of runner bar-containing fastener clips, the aforementionedrunner bar-containing analog to clip 31 could be substituted for runnerbar-less clip 31 and used with an appropriately dimensioned version of aconventional fastener dispensing tool of the type adapted for use withrunner bar-containing clips (an example of such a tool being anappropriately dimensioned Dennison® Mark II™ SWIFTACH® tool).

Referring now to FIGS. 4(a) through 4(c) and to FIG. 5, there are shownvarious views of a fastener dispensing tool that is particularlywell-suited for use in dispensing individual fasteners from clip 31,said fastener dispensing tool being constructed according to theteachings of the present invention and being represented generally byreference numeral 51. (Fasteners dispensed by tool 51 may be used tomaintain a dress shirt or the like in a folded condition or may be usedin other fastening applications.)

Tool 51 includes a hollow, gun-shaped casing 53, casing 53 comprising aright half 55 (which is shown separately in FIGS. 6(a) through 6(d)) anda left half 57 (which is shown separately in FIGS. 7(a) through 7(d)).Halves 55 and 57, which may be fabricated from any convenient durablematerial, such as molded plastic, are joined together by a plurality ofscrews 58 and jointly define a handle portion 59 and a barrel portion 61As seen best in FIG. 4(b), right half 55 and left half 57 also jointlydefine an opening 62 located at the front end of barrel portion 61, thepurpose of opening 62 to be discussed below.

Referring now to FIGS. 6(a) and 7(a), an oval-shaped recess 63-1 isprovided on the outer surface of the barrel portion of right half 55,and a corresponding oval-shaped recess 63-2 is provided on the outersurface of the barrel portion of left half 57. Recesses 63-1 and 63-2are adapted to receive complementary-shaped inserts 64-1 and 64-2,respectively, inserts 64-1 and 64-2 being shown disposed in theirrespective recesses in FIGS. 4(a) through 4(c). Inserts 64-1 and 64-2may bear a logo or the like and/or may have a rubberized or grippingouter surface to prevent tool 51 from sliding across a table when placedthereon.

Referring back to FIGS. 6(a) and 7(a), a window 65-1 is provided in thebarrel portion of right half 55, and a matching window 65-2 is providedin the barrel portion of left half 57. Windows 65-1 and 65-2 permit auser to monitor the status of a fastener clip 31 disposed inside casing53. In addition, windows 65-1 and 65-2 provide an opening through whichcross-bars 37 and 39 of a clip 31 may exit casing 53 once a clip 31 hasbeen completely spent.

An arrow 67-1 is formed on right half 55 towards the front of its barrelportion, and a matching arrow 67-2 is formed on left half 57 towards thefront of its barrel portion. Arrows 67-1 and 67-2 are aligned withopening 62 and are designed to aid a user in aligning tool 51 with anobject to be fastened, such as a dress-shirt.

Referring back to FIGS. 4(a) through 4(c) and to FIG. 5, tool 51 furthercomprises a door 69 (shown separately in FIGS. 8(a) through 8(d)). Door69, which also may be made from molded plastic or the like, is pivotallymounted at its front end on a screw 70 secured to halves 55 and 57. Whendoor 69 is closed, it substantially covers an opening formed betweenrecesses 55-1 and 57-1 located along the top edges of halves 55 and 57,respectively (recesses 55-1 and 57-1 seen best in FIGS. 6(d) and 7(d),respectively). For reasons to be revealed below, the rear end 69-1 ofdoor 69 is angled upwardly to permit limited access to the interior ofcasing 53 through an opening 68 even when door 69 is in a closedposition. When door 69 is pivoted away from the top of casing 53, theinterior of barrel portion 61 (and in particular the feed track to bedescribed below of casing 53) can be accessed.

As seen best in FIG. 5, a ring 71, which is preferably made of rubber orthe like, is rotatably mounted on a pin 72 fixed to door 69. Ring 71 isadapted to engage the filament portions of a clip 31 disposed withintool 51 in such a way as to permit manual advancement of a clip 31through the feed track of tool 51 merely by turning ring 71 from theexterior of casing 53.

Tool 51 further comprises an anvil 73 (shown separately in FIGS. 9(a)through 9(d)). Anvil 73, which is preferably made of molded plastic orthe like, includes a rear portion 73-1 and a front portion 73-2. Rearportion 73-1 is disposed within barrel portion 61 of casing 53 and issecured to halves 55 and 57 by screw 70 (anvil 73 sharing screw 70 withdoor 69). Hooked front portion 73-2 extends upwardly from the top ofcasing 53 and then loops downwardly in front of tool 51 spaced a shortdistance from opening 62. Front portion 73-2 is provided with an opening75, which is aligned with opening 62 and which is appropriately spacedfrom tool 51 so as to receive the tip of the needle of tool 51. Frontportion 73-2 is also provided with an outer slot 77 which is preferablydimensioned depthwise to extend beyond the tip of the needle in itsforwardmost position and is preferably dimensioned widthwise to preventa user from inserting his fingers thereinto. In this manner, anvil 73not only serves as a support for the fastening operation to be performedby tool 51 but also serves to protect a user from injury caused byaccidental needle sticks. As a further safety measure, the spacingbetween opening 62 of tool and opening 75 of anvil 73 is preferablysufficiently small (e.g., 0.25-0.3 inch) to prevent a user frominserting his fingers therebetween.

As can readily be appreciated, because anvil 73 is secured to casing 53by screw 70, anvil 73 can easily be replaced if damaged Also, anvil 73can readily be replaced with an anvil having a different sized loop ifone wishes to vary the point of attachment of the fastener dispensed bytool 51 into an object (i.e., generally speaking, the higher the loop,the lower the point of attachment of the fastener into the object).

As seen best in FIG. 5, tool 51 also includes a triggering mechanismwhose purpose will become apparent below. In the present embodiment,said triggering mechanism includes a trigger 81 Trigger 81 which may bemade of molded plastic or another similarly suitable material, ispivotally attached to casing 53 by a pin 83 and extends partiallythrough an opening 84 formed in handle portion 59 of casing 53 so thatit may be digitally manipulated for movement towards and away from,respectively, the rear wall of handle portion 59. A coiled spring 85,which is attached at one end to the inside rear wall of handle portion59 and which is attached at its opposite end to the inside of trigger81, biases trigger 81 away from the rear wall of handle portion 59.

The triggering mechanism of tool 51 additionally includes a lever 87 anda float link 89, both of which may be made of molded plastic or anothersuitable material. Lever 87 is disposed within casing 53 and ispivotally mounted at a first end 87-1 on a pin 88, pin 88 being fixed totrigger 81. Float link 89 is pivotally mounted at one end on a pin 90mounted inside handle portion 59 and is pivotally mounted at itsopposite end on a pin 91 fixed to an intermediate portion of lever 87.

Tool 51 further includes a needle assembly. In the present embodiment,said needle assembly comprises a needle 93. As seen best in FIGS. 10(a)through 10(c), needle 93 comprises a stem portion 95 and a base portion97. Stem portion 95, which may be made from stamped and rolled metal, isa generally cylindrical member terminating at one end in a sharp tip95-1 designed for insertion through a garment or like object. Stemportion 95 also has a slotted bore 95-2 extending substantiallylongitudinally thereacross. Base portion 97 may be made of a plasticthat has been insert-molded onto that end of stem portion 95 that isdistal to tip 95-1. (Alternatively, stem portion 95 and base portion 97may be a unitary structure made of metal or another suitable material.)Base portion 97 is provided with a slotted longitudinal bore 97-1 thatis aligned with bore 95-2 of stem portion 95 and is also provided with ascallop-shaped recess 99 on its outer surface whose purpose will bedescribed below. The bores of stem portion 95 and base portion 97 areappropriately dimensioned so that cross-bar 15 of a fastener 11 may beinserted thereinto from the rear of base portion 97, traverse the lengthof needle 93 through bore 95-2 and then exit needle 93 via tip 95-1. Theslots of stem portion 95 and base portion 97 are appropriatelydimensioned to permit the filament 13 of fastener 11 to extendtherethrough while its associated cross-bar 15 is disposed within needle93, said slots being oriented in tool 51 so as to face towards half 55of casing 53.

Referring back to FIG. 5, the needle assembly of tool 51 furthercomprises a needle carrier 101 (shown separately in FIGS. 11(a) through11(f), needle carrier 101 being slidably mounted in a slot 102 definedat least in part by matching sets of longitudinally extending ribs104-1/104-2 and 106-1/106-2 integrally formed on right half 55 and lefthalf 57, respectively, of casing 53 (ribs 106-1 and 106-2 being visiblein FIGS. 7(b) and 7(c)). One end of a spring 108 is attached to a post110 formed on needle carrier 101, the opposite end of spring 108 beingattached to a post 112 mounted in casing 53. In this manner, needlecarrier 101 is normally biased rearwardly in barrel portion 61. Needlecarrier 101, which may be made of molded plastic or another suitablematerial, is provided at its front end with a sleeve 107, sleeve 107being aligned with opening 62 for reasons to become apparent below. Baseportion 97 of needle 93 is disposed within sleeve 107 and is lockablysecured therewithin by a locking pin 109.

Referring now to FIG. 12, locking pin 109 can be seen to be a generallycylindrical member having a slotted head 111 (manipulable with ascrewdriver or the like) at one end thereof, a longitudinally-extendingslot 113 at the opposite end thereof and a scallop-shaped recess 115 onits outer surface at about its midpoint. Recess 115 on pin 109 isappropriately dimensioned to receive base portion 97 of needle 93, andrecess 99 of base portion 97 is appropriately dimensioned to receive pin109.

Locking pin 109 is disposed in a bore 117 formed in carrier 101, bore117 being shown in FIGS. 11(a) through 11(d) and in FIG. 11(f) As seenbest in FIG. 11(f), bore 117 and sleeve 107 are oriented relative to oneanother so that, when pin 109 is rotationally positioned so that recess115 faces away from needle 93, needle 93 is engaged by pin 109 and,therefore, is locked into sleeve 107 whereas, when pin 109 isrotationally positioned so that recess 115 faces towards needle 93,needle 93 is not engaged by pin 109 and, therefore, is free to beremoved from sleeve 107. As can be seen in FIG. 5, slotted head 111 oflocking pin 109 is accessible (for use in locking and unlocking needle93) through an opening 119 formed in the bottom of barrel portion 61.

Referring now to FIGS. 5 and 13, tool 51 further includes a mechanismfor loading fasteners, one at a time, into needle 93 and for ejectingloaded fasteners from needle 93. In the present embodiment, saidloading/ejecting mechanism comprises an ejector rod carrier 141, anejector rod 143 and an ejector clip 145. Ejector rod carrier 141 (shownseparately in FIGS. 14(a) and 14(b)), which may be made of moldedplastic or another suitable material, is slidably mounted on theunderside of needle carrier 101. Ejector rod carrier 141 is coupled tolever 87 by means of a pin 147 that is fixed to ejector rod carrier 141,lever 87 being pivotally mounted on pin 147. In this manner, whentrigger 81 is squeezed, ejector rod carrier 141 is moved forwardlyacross barrel portion 61; conversely, when trigger 81 is released,ejector rod carrier 141 is moved rearwardly across barrel portion 61.For reasons to be discussed below, the top of carrier 141 is shaped toinclude a first recessed portion 149-1 at its front end and a secondrecessed portion 149-2 proximate to its rear end.

Ejector rod 143 is preferably conventional in shape and composition. Therear end of ejector rod 143 is mounted in the front end of carrier 141,the front end of ejector rod 143 extending forwardly away from carrier141 and being aligned with bore 97-1 of needle 93. In this manner, whentrigger 81 is squeezed, ejector rod carrier 141 and ejector rod 143together move forwardly through barrel portion 61 until the front end ofejector rod 143 is inserted completely through needle 93 Because, aswill hereinafter be described, the cross-bar 15 of the lead fastener 11of a fastener clip 31 loaded in tool 51 is positioned behind bore 97-1of needle 93, as the front end of ejector rod 143 moves forwardlythrough barrel portion 61, it pushes said cross-bar into and throughneedle 93, in the process severing the connector 33 between saidcross-bar and its adjacent cross-bar 15.

Ejector clip 145, which is shown separately in FIG. 15, is preferably aunitary structure made of stamped stainless steel or the like. Clip 145,which is positioned between the right side of ejector carrier 141 andthe inner right side of needle carrier 101, is shaped to include a frontportion 151-1 and a rear portion 151-2. Front portion 151-1 is providedwith a tip 152, tip 152 being aligned with cross-bar 17 of the leadfastener 11. Rear portion 151-2 is provided with an elongated slot 153through which pin 147 extends. As can be seen best in FIG. 15, the rearend 153-1 of slot 153 is angled upwardly. In this manner, as ejector rodcarrier 141 begins its forward movement through barrel portion 61 and asthe front end of ejector rod 143 pushes cross-bar 15 of the leadfastener into needle 93, pin 147 begins to move forwardly through slot153 from rear end 153-1, causing clip 145 to be moved forwardly a shortdistance and causing tip 152 of clip 145 to engage cross-bar 17 of thelead fastener and to push it forwardly until the connector 35 connectingcross-bar 17 to the remainder of the clip 31 breaks. As carrier 141continues to move forwardly, pin 147 moves through the straight frontend 153-2 of slot, causing clip 145 to remain stationary while carrier141 moves forwardly Later, as carrier 141 makes its rearward movementthrough barrel portion 61 (as trigger 81 is released), pin 147 movesrearwardly through slot 153, and clip 145 is restored to its originalposition.

Referring back to FIGS. 5 and 13, tool 51 further comprises a mechanismfor coupling and decoupling ejector rod carrier 141 to and from needlecarrier 101. In the present embodiment, said mechanism comprises alinking member 161 (shown separately in FIG. 16). Linking member 161,which may be made of molded plastic or a similarly suitable material, isseated in a slot 142 (shown best in FIGS. 11(a) and 11(b)) formed inneedle carrier 101 and is pivotally mounted at one end 161-1 to needlecarrier 101 by a pin 163.

As seen best in FIG. 13, the front end 161-2 of linking member 161 isenlarged and, prior to actuation of trigger 81, is disposed over therecessed portion 149-1 of carrier 141. When trigger 81 is firstsqueezed, carrier 141 moves forwardly: however, because of recessedportion 149-1, carrier 141 does not initially engage the enlarged frontend 161-2 of linking member 161 As a result, linking member 161 and, inturn, needle carrier 101 are not initially coupled to carrier 141 and donot initially move forwardly with carrier 141. During the aforementionedpart of the trigger stroke, ejector rod 143 severs the lead cross-bar 15from its adjacent cross-bar 15 and feeds the lead cross-bar 15 intoneedle 93.

Continued squeezing of trigger 81 causes that portion of carrier 141located immediately behind recessed portion 149-1 to pivot front end161-2 of linking member 161 up against rib 104-1, thereby causinglinking member 161 and, in turn, needle carrier 101 to be coupled tocarrier 141. Thus, once coupled together, carrier 101, linking member161 and carrier 141 begin to move forwardly together through slot 102.During this part of the trigger stroke, needle 93 and ejector rod 143move together, with tip 95-1 of needle 93 passing through opening 62 ofcasing 53 and through opening 75 of anvil 73.

Further continued squeezing of trigger 81 causes linking member 161 andcarrier 141 to be decoupled as front end 161-2 of linking member 161arrives at and is forced through an opening 165 formed in rib 104-1 (acorresponding opening being provided in rib 106-1) while carrier 141continues to move forwardly through barrel portion 61. During this partof the trigger stroke, ejector rod 143 continues to move forwardlythrough the now-stationary needle 93.

Still further continued squeezing of trigger 81 causes ejector carrier141 to slide across the now-stationary enlarged end 161-2 of member 161until enlarged end 161-2 drops down into recessed portion 149-2 ofcarrier 141. During this part of the trigger stroke, ejector rod 143completes its forward progress through needle 93.

When trigger 81 is initially released, carrier 141 and member 161 moverearwardly together (with enlarged end 161-2 disposed in recessedportion 149-2 and pressed up against rib 104-1) until member 161 isfully withdrawn and enlarged end 161-2 is aligned with an opening 166 inrib 104-1 (a corresponding opening being provided in rib 106-1). Duringthis part of the trigger stroke, ejector rod 143 and needle 93 moverearwardly together, with needle 93 being completely withdrawn intocasing 53 through opening 62. The primary reason for having needle 93and ejector rod 143 simultaneously withdraw at the beginning of thetrigger release, instead of simply reversing the sequence of events thattook place during the squeezing of trigger 81 (which would involvehaving ejector rod 143 first retract partially while needle 93 is keptstationary), is to prevent the cross-bar 15 that is being dispensedthrough needle 93 from toggling back into the needle 93 after retractionof ejector rod 143. This undesired outcome is prevented in the presentarrangement by having needle 93 and ejector rod 143 retract togetheruntil needle 93 has fully retracted.

Continued release of trigger 81 causes carrier 141 to slide rearwardlyacross the now-stationary enlarged end 161-2 until carrier 141 is fullywithdrawn and enlarged end 161-2 is returned to its starting positionover recessed portion 149-1. During this part of the trigger stroke,ejector rod 143 fully retracts.

Tool 51 further comprises a feed track 171 along which a fastener clip31 may be advanced through tool 51 to a position where individualfasteners can be loaded into and dispensed from needle 93. Feed track171, which extends from the rear of opening 68 to just behind bore 97-1of needle 93, is defined, in part, by a matching pair of arcuate ribs173-1 and 173-2 formed interiorly along the barrel portion of halves 55and 57, respectively, and is defined, in part, by a feed guide 175(shown separately in FIGS. 17(a) through 17(c)) stationarily mounted inbarrel portion 61 just behind needle 93. Feed track 171 is appropriatelydimensioned so that the entirety of a clip analogous to clip 31 butcomprising one hundred twenty-five fasteners 11 can be completelycontained within tool 51. As can readily be appreciated, even longerfastener clips (e.g., clips having several hundred fasteners 11) can bedisposed in feed track 171, with the rear end of such clips extendingout through opening 68 of tool 51.

Referring now to FIGS. 17(a) through 17(c), feed guide 175, which ispreferably a unitary structure made of molded plastic or the like, isshaped to include a front portion 177-1, a rear portion 177-2 and anintermediate portion 177-3 Front portion 177-1 is provided with aslotted bore 179, which is aligned with bore 97-1 of needle 93 and whichis also aligned with ejector rod 143, and is also provided with a slot180, which is aligned with tip 152 of clip 145 In addition, the frontsurface of front portion 177-1 is shaped to include a recessed area 181,which is adapted to receive the rear of base portion 97 of needle 93 asneedle 93 is moved back and forth by needle carrier 101. Furthermore,the rear surface of front 177-1 is shaped to include a guide rib 183,guide rib 183 being positioned in feed track 171 and being appropriatelydimensioned to keep cross-bars 15 and 17 properly aligned on oppositesides thereof as a clip 31 travels downwardly through feed track 171. Adownwardly and outwardly angled bump 183-1 is provided on rib 183, bump183-1 being positioned on rib 183 and appropriately dimensioned so thatthe filament 15 of the lead fastener 11 slides thereacross as saidfastener moves into position to be dispensed but, once drawn past bump183-1, cannot easily be pulled back thereover. In this manner, bump183-1 acts as an anti-back to prevent a clip 31 from moving backwards infeed track 171 during the as yet to be described feeding operation ofthe clip.

The top surface of intermediate portion 177-3 constitutes the front endof feed track 171 and functions as a stage on which the lead fastener 11of clip 31 is situated prior to being dispensed by tool 51.

A pair of transverse openings 185-1 and 185-2 are provided in rearportion 177-2 of guide 175, opening 185-1 being positioned so that it isaligned both with ejector rod 143 and with bore 179, opening 185-2 beingpositioned so that it is aligned with tip 152 of clip 145 and with slot180.

As cross-bar 15 of the lead fastener 11 is pushed by ejector rod 143through opening 179, the severable connector 33 connecting saidcross-bar 15 to its adjacent cross-bar 15 is severed. Likewise, ascross-bar 17 of the lead fastener 11 is pushed by ejector clip 145through slot 180, the severable connector 35 connecting said cross-bar17 to its adjacent cross-bar 17 is severed. As noted above, oneadvantage to having connectors 33 and 35 taper in the manner describedabove is that, once connectors 33 and 35 between the lead fastener andits adjacent fastener have been severed and the lead fastener has beendispensed, the cross-bars 15 and 17 of the adjacent fastener are capableof sitting substantially flush on top of the top surface of portion177-3. As also noted above, cross-bars 37 and 39 ensure that cross-bars15 and 17 of the last fastener 11 of clip 31 remain properly alignedwith bore 179 and slot 180, respectively.

Referring back now to FIG. 13, tool 51 further comprises a feed clip187, clip 187 being mounted on guide 175 for use in maintaining thealignment of cross-bar 15 of the lead fastener 11 with bore 179 whilesaid cross-bar 15 is seated on top of portion 177-3 of guide 175. Asseen best in FIGS. 18(a) and 18(b), clip 187 is a unitary structure,preferably made of molded plastic, comprising a main portion 189-1 andan arm 189-2. Main portion 189-1 is provided with a pair of mountingposts 190-1 and 190-2 insertable into a pair of corresponding openings191-1 and 191-2 formed in guide 175. Arm 189-2, which is biased awayfrom main portion 189-1, is shaped to include a finger 192 adapted toengage cross-bar 15 of the lead fastener 11.

Referring back now to FIG. 13, tool 51 further comprises a mechanism forfeeding or advancing a clip 31 through feed track 171 at a rate of onefastener per trigger stroke. In the present embodiment, said feeding oradvancing mechanism comprises a pawl 193 made of molded plastic or asimilarly suitable material. Pawl 193, which is shaped to include a pairof fingers 194-1 and 194-2 (see FIG. 19) engageable with the filamentportion 15 of a clip 31 seated in guide 175, is rotatably mounted onguide 175 by a pin 195. In addition, pawl 193 is mechanically coupled bya wire hook 197 to a feed sliding member 199 (shown separately in FIG.20) slidably mounted in a slot defined by ribs 203-1/203-2 and205-1/205-2 on halves 55 and 57, respectively, of casing 53 (ribs 205-1and 205-2 being shown in FIGS. 7(b) and 7(c)). A rear post 207 is formedat the rear end of member 199, and a front post 209 is formed proximateto the front end of member 199. Posts 207 and 209 are appropriatelypositioned on member 199 so that, when trigger 81 is nearly completelysqueezed, lever 87 contacts post 209 and moves member 199 forwardly ashort distance. This causes pawl 193 to rotate away from the fastenerspositioned in guide 175. Then, when trigger 81 is released, lever 87contacts post 207 and moves member 199 rearwardly a short distance Thiscauses pawl 193 to rotate towards the fasteners positioned in guide 175,whereby fingers 194-1 and 194-2 engage the filament portion of the clipand pull the clip down to advance it by one fastener.

To prepare tool 51 for use, clip 31 (or more preferably a fastener clipanalogous to clip 31 but comprising on the order of one hundredtwenty-five fasteners 11) is loaded into tool 51. This is typically doneby opening door 69, inserting the clip into feed track 171 (i.e., byorienting the clip relative to ribs 173-1 and 173-2 so that therespective filaments 15 are disposed on top of and across ribs 173-1 and173-2 and so that the respective cross-bars 15 and 17 are positioned offto the sides of and perpendicular to ribs 173-1 and 173-2), closing door69, and advancing the clip through feed track 171 using wheel 71 Withtool 51 thus loaded, a fastener 11 may be inserted into a desiredarticle first by placing the article between opening 62 in casing 53 andopening 75 in anvil 73 (arrows 67-1 and 67-2 optionally being used tolocate openings 62 and 75) and then by squeezing and releasing trigger81 in the manner described above.

The embodiments of the present invention recited herein are intended tobe merely exemplary and those skilled in the art will be able to makenumerous variations and modifications to it without departing from thespirit of the present invention. All such variations and modificationsare intended to be within the scope of the present invention as definedby the claims appended hereto.

1. A method of fixing an article of clothing to itself, said methodcomprising the steps of: (a) providing a plastic fastener, said plasticfastener comprising (i) a flexible filament, said flexible filamenthaving a first end, a second end, and a length, said length beingsuitable to fixedly retain the article of clothing against itself, (ii)an inserting element disposed at said first end, said inserting elementbeing dimensioned to enable its insertion through the article ofclothing and, once inserted therethrough, to be retained by the articleof clothing, and (iii) a retaining element disposed at said second end,said retaining element being dimensioned to prevent said flexiblefilament from being pulled completely through the article of clothing;and (b) inserting said inserting element of said plastic fastener intoand completely through the article of clothing at at least a pair oflocations therein, with said retaining element not being inserted intothe article of clothing.
 2. The method as claimed in claim 1 whereinsaid flexible filament has a tensile strength of 2-4 lbs.
 3. The methodas claimed in claim 2 wherein said flexible filament has a tensilestrength of 2 lbs.
 4. The method as claimed in claim 1 wherein saidflexible filament has a length of approximately 3-5 mm.
 5. The method asclaimed in claim 4 wherein said flexible filament has a length ofapproximately 4.3 mm.
 6. The method as claimed in claim 1 wherein thearticle of clothing is a dress shirt and wherein said flexible filamenthas a tensile strength of 2-4 lbs. and a length of approximately 3-5 mm.7. The method as claimed in claim 6 wherein said flexible filament has atensile strength of 2 lbs. and a length of approximately 4.3 mm.
 8. Amethod of fixing an article of commerce to a support, wherein thearticle of commerce is a dress shirt and wherein the support is acardboard backing, said method comprising the steps of: (a) providing aplastic fastener, said plastic fastener comprising (i) a flexiblefilament, said flexible filament having a first end, a second end and alength, said length being suitable to fixedly retain the article ofcommerce against the support (ii) an inserting element disposed at saidfirst end, said inserting element being dimensioned to enable itsinsertion through the article of commerce and the support and, onceinserted therethrough, to be retained thereby, and (iii) a retainingelement disposed at said second end, said retaining element beingdimensioned to prevent said flexible filament from being pulledcompletely through the article of commerce and the support; and (b)inserting said inserting element of said plastic fastener into andcompletely through the article of commerce and the support, with saidretaining element not being inserted into either the article or thesupport, in such a way as to fix the article of commerce to the support.9. The method as claimed in claim 8 wherein said flexible filament has atensile strength of 2-4 lbs.
 10. The method as claimed in claim 9wherein said flexible filament has a tensile strength of 2 lbs.
 11. Themethod as claimed in claim 10 wherein said flexible filament has alength of approximately 3-5 mm.
 12. The method as claimed in claim 11wherein said flexible filament has a length of approximately 4.3 mm. 13.The method as claimed in claim 8 wherein said flexible filament has atensile strength of 2-4 lbs. and a length of approximately 3-5 mm.
 14. Amethod of coupling an article of commerce to a support, said methodcomprising the steps of: (a) providing a plastic fastener, said plasticfastener comprising (i) a flexible filament, said flexible filamenthaving a first end, a second end, a tensile strength of approximately2-4 lbs. and a length of approximately 3-5 mm; (ii) an inserting elementdisposed at said first end, said inserting element being dimensioned toenable its insertion through the article of commerce and the supportand, once inserted therethrough, to be retained thereby, and (iii) aretaining element disposed at said second end, said retaining elementbeing dimensioned to prevent said flexible filament from being pulledcompletely through the article of commerce and the support in thedirection of said inserting element; and (b) inserting said insertingelement of said plastic fastener into and completely through the articleof commerce and the support.
 15. A method of fixing together twoelements, said method comprising the steps of: (a) providing a plasticfastener, said plastic fastener comprising (i) a flexible filament, saidflexible filament having a first end, a second end, a length and atensile strength, said length being suitable to fix the two elementstogether, said tensile strength being sufficiently strong to keep thetwo elements fixed together during normal handling and yet sufficientlyweak to enable the two elements to be separated from one another withoutbeing damaged by said plastic fastener merely by having the two elementspulled away from each other until said flexible filament breaks, (ii) aninserting element disposed at said first end, said inserting elementbeing dimensioned to enable its insertion through the two elements and,once inserted therethrough, to be retained by the two elements, and(iii) a retaining element disposed at said second end, said retainingelement being dimensioned to prevent said flexible filament from beingpulled completely through the two elements; and (b) inserting saidinserting element of said plastic fastener into and completely throughthe two elements, with said retaining element not being inserted intothe two elements.
 16. The method as claimed in claim 15 wherein said twoelements are different portions of a single article of clothing.
 17. Themethod as claimed in claim 16 wherein said article of clothing is adress shirt.
 18. The method as claimed in claim 17 wherein said lengthof said flexible filament is approximately 4.3 mm and wherein saidtensile strength of said flexible filament is approximately 2 lbs. 19.The method as claimed in claim 15 wherein one of said two elements is anarticle of clothing and wherein the other of said two elements is acardboard support.
 20. The method as claimed in claim 19 wherein saidarticle of clothing is a dress shirt.
 21. The method as claimed in claim20 wherein said length of said flexible filament is approximately 4.3 mmand wherein said tensile strength of said flexible filament isapproximately 2 lbs.
 22. The method as claimed in claim 20 wherein saidarticle of clothing is an article of clothing for a doll.
 23. The methodas claimed in claim 22 wherein said article of clothing is a doll'sdress.
 24. The method as claimed in claim 20 wherein said length of saidflexible filament is approximately 4.3 mm and wherein said tensilestrength of said flexible filament is approximately 2 lbs.
 25. Themethod as claimed in claim 15 wherein said two elements are two articlesof clothing.
 26. The method as claimed in claim 25 wherein said twoelements are a pair of socks.
 27. The method as claimed in claim 15wherein said two elements are two sheets of paper.
 28. A method ofcoupling together two or more sheets of paper, said method comprisingthe steps of: (a) providing a plastic fastener, said plastic fastenercomprising (i) a flexible filament, said flexible filament having afirst end, a second end, a length and a tensile strength, said tensilestrength being sufficiently strong to keep the sheets of paper coupledtogether during normal handling and yet sufficiently weak to enable thesheets of paper to be separated from one another without being damagedby said plastic fastener merely by pulling the sheets of paper away fromeach other until said flexible filament breaks, (ii) an insertingelement disposed at said first end, said inserting element beingdimensioned to enable its insertion through the sheets of paper and,once inserted therethrough, to be retained by the sheets of paper, and(iii) a retaining element disposed at said second end, said retainingelement being dimensioned to prevent said flexible filament from beingpulled completely through the sheets of paper; and (b) inserting saidinserting element of said plastic fastener into and completely throughthe sheets of paper, with said retaining element not being inserted intothe sheets of paper.